Machine detection system

ABSTRACT

A method of mapping a machine having a work tool includes sensing an outer boundary of the machine and generating a first set of information indicative of the outer boundary of the machine, moving the work tool relative to the machine through substantially an entire range of motion of the work tool, and sensing an outer boundary of the work tool during movement of the work tool through substantially the entire range of motion. The method also includes generating a second set of information indicative of a location of the outer boundary of the work tool through substantially the entire range of motion, determining information indicative of a position of an object disposed proximate the machine, and determining whether the information indicative of the position of the object is included in either the first or second sets of information.

TECHNICAL FIELD

The present disclosure relates generally to a detection system, and moreparticularly, to a detection system associated with a mobile machine.

BACKGROUND

Machines used in mine sites and other like worksites can be large,complex, and relatively difficult to operate. For example, such machinesmay include one or more operator stations where a machine operator maysit during operation of the machine. While such operator stations aretypically located at a central location on the machine to provide theoperator with as much visibility as possible, such operator stations areinevitably characterized by one or more blind spots. For example, due tothe size of the machines used in mine sites and other like worksites, anoperator sitting in an operator station may not be able to see objectslocated in close proximity to the front end, rear end, and/or sides ofthe machine. Such machines may also include one or more ladders,railings, chains, safety covers, engine compartments, and/or other likecomponents that may further hinder operator visibility.

Additionally, such machines may include work tools and/or other likecomponents configured to assist in removing, hauling, moving, and/orotherwise handling large quantities of earthen material at the worksite.Such material may include, for example, dirt, rocks, sand, pavement,and/or minerals typically associated with such worksites. Due to thesize and maneuverability of the work tools connected to the machine,however, an operator sitting in an operator station may not be able tosee objects located in close proximity to the work tool.

In order to mitigate the risks associated with such blind spots,worksite machines typically employ a detection system configured tosense objects located in close proximity to the machine. Such anexemplary system is disclosed in U.S. Patent Application Publication No.US 2011/0268247 to Shedlock et al. (“the '247 publication”). The '247publication teaches a scanning apparatus including an X-ray detectorsystem. The detector system is configured to scan the environmentproximate the scanning apparatus in response to user input, and togenerate an image of a scanned object.

While the scanning apparatus of the '247 publication may be configuredto generate one or more images of various objects, such systems are notconfigured to address the blind spot problems described above. Forexample, in machines employing a machine detection system, a scanningapparatus similar to that described in the '247 publication may bepositioned on top of the operator station and/or at various otherlocations on the machine. During calibration of these systems, thescanning apparatus may detect one or more of the ladders, railings,chains, safety covers, engine compartments, and/or other components ofthe machine described above. In order to avoid unnecessarily notifyingthe operator of such components during operation of the machine, one ormore software-based filters may be created for use with the machinedetection system. Such filters may, for example, define regions on oraround the machine within which detection is not possible due to thelocation or configuration of the scanning apparatus. As is the case inthe example above, such filters may also define regions on or around themachine within which detected objects will be intentionally ignored toavoid falsely alarming the operator.

For ease of configuration and calibration, machines of various typesoften employ the same (i.e., a general/universal) software-based filterfor use in conjunction with such machine detection systems. Thisuniversal filter is designed to be larger than necessary to account forvariations in the size, number, location, and/or configurations of thevarious components attached to worksite machines. Portions of theuniversal filter are also enlarged to account for variations in thesize, number, type, range of motion, and/or configurations of thevarious different work tools used with such machines. As a result, theuniversal filter typically employed by such machine detection systemsmay avoid notifying the operator of machine components, fixtures, orwork tools during operation. However, since such universal filters arenot tailored to closely match the particular configuration of themachine on which the machine detection system is used, such universalfilters lack a desirable level of sensitivity.

The disclosed systems and methods are directed to overcoming one or moreof the problems set forth above and/or other problems of the prior art.

SUMMARY

In an exemplary embodiment of the present disclosure, a method ofmapping a machine having a work tool includes sensing an outer boundaryof the machine and generating a first set of information indicative ofthe outer boundary of the machine, moving the work tool relative to themachine through substantially an entire range of motion of the worktool, and sensing an outer boundary of the work tool during movement ofthe work tool through substantially the entire range of motion. Themethod also includes generating a second set of information indicativeof a location of the outer boundary of the work tool throughsubstantially the entire range of motion, determining informationindicative of a position of an object disposed proximate the machine,and determining whether the information indicative of the position ofthe object is included in either the first or second sets ofinformation.

In another exemplary embodiment of the present disclosure, a method ofmapping a machine having a first work tool includes sensing, at aworksite, an outer boundary of the machine with a plurality of sensorslocated on the machine, generating a first set of information indicativeof the outer boundary of the machine, and moving the first work toolrelative to the machine through substantially an entire range of motionof the first work tool. The method also includes sensing, at theworksite, an outer boundary of the first work tool during movement ofthe first work tool through substantially the entire range of motionwith at least one sensor of the plurality of sensors, and generating asecond set of information indicative of a location of the outer boundaryof the first work tool through substantially the entire range of motion.The method further includes forming, at the worksite, an electronic mapassociated with the machine based on the first and second sets ofinformation. The map is indicative of the outer boundary of the machine,the outer boundary of the first work tool, and substantially the entirerange of motion. The method also includes determining informationindicative of a position of an object at the worksite, and determiningwhether the object is located within the map based on the informationindicative of the position of the object.

In a further exemplary embodiment of the present disclosure, a machineincludes a frame, at least one traction device configured to support theframe and propel the machine about a worksite, and a work tooloperatively connected to the frame and configured to move, relative tothe frame, through a range of motion. The machine also includes a sensormounted on the machine. The sensor is configured to generate a first setof information indicative of an outer boundary of the machine and asecond set of information indicative of a location of an outer boundaryof the work tool through substantially the entire range of motion. Themachine further includes a controller disposed on the machine and incommunication with the sensor. The controller is configured to generatean electronic map associated with the machine based on the first andsecond sets of information. The map is indicative of the outer boundaryof the machine, the outer boundary of the work tool, and substantiallythe entire range of motion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic illustration of an exemplary disclosed machine;and

FIG. 2 is a schematic illustration of an exemplary detection system thatmay be used with the machine of FIG. 1.

DETAILED DESCRIPTION

FIG. 1 illustrates an exemplary machine 10 operating at a worksite 12.Machine 10 may be a mobile machine that performs some type of operationassociated with an industry such as mining, construction, farming,transportation, or any other industry known in the art. Exemplaryoperations include, among others, carrying, digging, dozing, hauling,ripping, grading, excavating, scraping, etc. Accordingly, machine 10 maybe an earth moving machine such as a carry dozer (shown in FIG. 1), ascraper, a tractor, a wheel loader, a haul truck, a motor grader, or anyother machine known in the art that is configured to move earthenmaterial at worksite 12. Machine 10 may generally include a frame 14that at least partially defines or supports an operator station 16, oneor more engines 18 mounted to frame 14, a plurality of traction devices20 driven by engine 18 to propel machine 10, and one or more work tools22 operatively connected to frame 14 and powered by engine 18.

Operator station 16 may be equipped with one or more interface devices24 located proximate an operator seat (not shown) and configured toexchange information (e.g., performance data, worksite records, controlcommands, etc.) with an operator of machine 10. These interface devices24 may include, among other things, a monitor, a joystick, a pedal, akeypad, a button, a wheel, a lever, and/or any other device known in theart. Interface devices 24 may be configured to generate and receivesignals corresponding with the information exchange.

In the exemplary embodiment of FIG. 1, one of interface devices 24 mayinclude a monitor that provides a graphics user interface (GUI) forpresentation of worksite information. The monitor may be a computerconsole or cab-mounted monitor, an LCD screen, a plasma screen, oranother similar device that receives instructions and displayscorresponding information. It is contemplated that the monitor may alsobe configured to receive input from the operator regarding desired modesand/or display functionality, for example by way of a touch screeninterface or physical buttons and switches, if desired. Such monitorsmay be configured to display, for example, one, two, and/orthree-dimensional images.

Engine 18 may be an internal combustion engine configured to combust amixture of fuel and air to produce a mechanical power output. Forexample, engine 18 may include a diesel engine, a gasoline engine, agaseous fuel-powered engine, or another type of combustion engineapparent to one skilled in the art. It is contemplated, however, thatengine 18 may alternatively embody a non-combustion source of power suchas a fuel cell, a battery, a tether cable, or another source known inthe art.

Traction devices 20, in the disclosed embodiment, are tracks located atopposing sides 36 of machine 10. Each track may be independently drivento turn machine 10 or simultaneously and dependently driven to propelmachine 10 in a straight direction. It is contemplated that one or allof traction devices 20 may be replaced with another type of tractiondevice, if desired, such as belts or wheels. In these situations,steering of machine 10 may be implemented by pivoting and/or tilting thetraction devices, as is known in the art.

Work tool 22 may be supported by frame 14, powered by engine 18, andcontrollable and/or monitored via interface devices 24. Work tool 22 mayinclude any device used to perform a particular task such as, forexample, a bucket (shown in FIG. 1), a blade, a fork arrangement, ashovel, a dump bed, or any other task-performing device known in theart. Although connected to a front end 26 of machine 10 in theembodiment of FIG. 1 to lift, pivot, and/or tilt relative to machine 10and/or frame 14, work tool 22 may alternatively or additionally rotate,slide, extend, or move in another manner known in the art. In furtherexemplary embodiments, one or more additional work tools 22 may also beconnected to a rear end 30 and/or at least one of the sides 36 ofmachine 10 for such movement.

One or more sensors 30 a, 30 b, 30 c may be associated with machine 10and/or work tool 22 to sense one or more characteristics thereof. In thedepicted example, two sensors 30 a are associated with front end 26 ofmachine 10, an additional sensor 30 b is associated with side 36 ofmachine 10, and at least one sensor 30 c is associated with rear end 30.In additional exemplary embodiments, any number or combination ofsensors 30 a, 30 b, 30 c may be disposed proximate and/or otherwiseassociated with front end 26, rear end 30, and one or both sides 36 ofmachine 10. Sensors 30 a, 30 b, 30 c may embody a camera, a radardevice, thermal radiation detectors, optical radiation detectors, and/orany other sensors known in the art. In exemplary embodiments, sensors 30a, 30 b, 30 c may be configured to generate an image of the portion ofthe machine 10 with which the respective sensor 30 a, 30 b, 30 c isassociated. For example, sensors 30 a disposed proximate front end 26may each be configured to generate an image of, sense, monitor, collectradiation in the optical and/or thermal band, and/or otherwise determinea characteristic associated with front end 26. In exemplary embodiments,such characteristics may comprise characteristics of and/or associatedwith worksite 12. For example, sensors 30 a, 30 b, 30 c may each beconfigured to determine the presence and/or location of one or moreobjects 40 (FIG. 2) associated with the worksite 12 and positionedproximate machine 10. For example, sensors 30 a, 30 b, 30 c may beconfigured to determine the presence and/or location of an operator,another machine 10, a large boulder or other impediment, and/or otherobjects 40 typically present at worksite 12 and proximate machine 10. Itis also contemplated that images produced and/or other informationcollected by sensors 30 a, 30 b, 30 c may be used to help determine theidentification of such objects 40, if desired. For example, a particularcolor, size, shape, and/or other characteristic of the object, asdetermined by one or more of the sensors 30 a, 30 b, 30 c, may beprocessed by a controller 28 in communication with sensors 30 a, 30 b,30 c to determine the identification thereof. It is contemplated thatadditional and/or different sensors may be associated with machine 10,if desired, and one or more of sensors 30 a, 30 b, 30 c may be of adifferent type and/or configuration than a remainder of the sensors 30a, 30 b, 30 c employed by machine 10.

In further exemplary embodiments, sensors 30 a, 30 b, 30 c may beconfigured to sense an outer boundary of machine 10 and/or work tool 22.In such embodiments, sensors 30 a, 30 b, 30 c may be configured togenerate one or more sets of information indicative of the outerboundary of machine 10 and indicative of the outer boundary of work tool22. Such information may comprise distance, angle, rotation, speed,direction, acceleration, deceleration, and/or other like informationtypically associated with a machine 10 and/or a work tool 22. As usedherein, the term “outer boundary” may be defined as the outermostsurface of the object in question. Accordingly, the outer boundary ofmachine 10 may include the outer surface of frame 14, operator station16 and/or one or more work tools 22 connected thereto. The outerboundary of machine 10 may also include the outer surface of anysignage, ladders, railings, safety covers, walkways, steps, and/or othercomponents of machine 10. Similarly, the outer boundary of work tool 22may include the outer surface thereof as well as any blades, groundengaging tools, brackets, linkages, hydraulic actuation devices,pneumatic actuation devices, and/or any other components of work tool22.

In exemplary embodiments, a first set of information may be indicativeof the outer boundary of machine 10, and may include, for example,information indicative of a position of one or more machine components.Additionally, a second set of information may be indicative of the outerboundary of work tool 22, and may include, for example, informationindicative of a position of work tool 22 relative to machine 10. Inexemplary embodiments in which work tool 22 is configured to moverelative to machine 10, such a second set of information may includeinformation indicative of a location of the outer boundary of work tool22 through substantially an entire range of motion of work tool 22. Itis understood that various different work tools 10 may be connected tomachine 10 during use to assist in accomplishing associated tasks atwork site 12. Accordingly, upon replacing a first work tool 22 with asecond work tool 22 different than the first, sensors 30 a, 30 b, 30 cmay be configured to generate respective sets of information indicativeof the outer boundary of the second work tool 22.

In each of the embodiments described herein, sensors 30 a, 30 b, 30 cmay each be configured to determine the presence, position, and/orlocation of one or more components of machine 10 and/or work tool 22.For example, sensors 30 a, 30 b, 30 c may each generate a respectivesubset of information unique to the sensor. In exemplary embodiments,the sets of information described above may comprise such respectivesubsets of information. Each subset of information may includeinformation generated by the respective sensor indicative of a positionof one or more machine components as seen by the respective sensor. Forexample, a first sensor 30 a disposed proximate front end 26 maygenerate a first subset of information indicative of a position of arailing of machine 10. A second sensor 30 a disposed proximate front end26 but spaced from the first sensor 30 a may generate a second subset ofinformation indicative of a position of the railing as seen by thesecond sensor 30 a. Although first and second sensors 30 a may beconfigured to sense an outer boundary of machine 10 and generaterespective subsets of information including information indicative ofthe position of the same railing or other machine component, theposition information in the respective subsets may be different due tothe different positions of the first and second sensors 30 a relative tothe railing. In further exemplary embodiments, each subset ofinformation may include information generated by the respective sensors30 a, 30 b, 30 c indicative of a position of one or more objects 40located at worksite 12 as seen by the respective sensor.

Controller 28, together with interface device 24 and sensors 30 a, 30 b,30 c may constitute a machine detection system 32 configured to generateand/or otherwise form, at worksite 12, one or more narrowly-tailoredelectronic maps 34 (FIG. 2) particular to machine 10. Controller 28 mayembody a single or multiple microprocessors, field programmable gatearrays (FPGAs), digital signal processors (DSPs), etc., that are capableof analyzing input information received from sensors 30 a, 30 b, 30 cand responsively generating and updating one or more electronic maps 34based on the analysis. Numerous commercially available microprocessorscan be configured to perform the functions of controller 28. It shouldbe appreciated that controller 28 could readily embody a microprocessorseparate from that controlling other functions of machine 10 andworksite 12, or that controller 28 could be integral with a generalmachine and/or worksite microprocessor and be capable of controllingnumerous machine and/or worksite functions and modes of operation. If aseparate microprocessor, controller 28 may communicate with the generalmachine and/or worksite microprocessor(s) via datalinks, wirelesscommunications, or other methods. Various other known circuits may beassociated with controller 28, including power supply circuitry,signal-conditioning circuitry, actuator driver circuitry (i.e.,circuitry powering solenoids, motors, or piezo actuators), andcommunication circuitry.

Electronic map 34 may be stored in the memory of controller 28 andselectively displayed on interface device 24. Electronic map 34 mayinclude a collection of data in the form of tables, graphs, and/orequations. For example, electronic map 34 may comprise a two orthree-dimensional map associated with machine 10 and based on one ormore sets and/or subsets of information received from sensors 30 a, 30b, 30 c. In such embodiments, electronic map 34 may be indicative of theouter boundary of machine 10, the outer boundary of work tool 22, and/orsubstantially an entire range of motion of work tool 22 relative tomachine 10. Electronic map 34 may comprise a two-dimensional graphicalrepresentation of worksite 12 and/or machine 10. Additionally, as shownin FIG. 2, electronic map 34 may comprise a three-dimensional graphicalrepresentation of worksite 12 and/or machine 10, with locations and/orpositions of respective machine components, work tool 22 and/or one ormore objects 40 marked on the representation. Controller 28 may beconfigured to automatically generate and/or update electronic map 34, inreal time during operation of machine 10. Alternatively, as will bedescribed in greater detail below, controller 28 may be configured toform electronic map 34, at worksite 12, during calibration of machine 10prior to operation. Controller 28 may also be configured to allow theoperator of machine 10 to directly modify electronic map 34 and/or toselect display parameters from available parameters stored in the memoryof controller 28. It is contemplated that the modifications and/ordisplay parameters may additionally or alternatively be automaticallyimplemented and/or selectable based on modes of machine calibrationand/or operation, if desired.

In one embodiment, controller 28 may be located onboard machine 10. Inthis embodiment, controller 28 may receive direct input from sensors 30a, 30 b, 30 c also located onboard machine 10 and may cause electronicmap 34 to be displayed locally on interface device 34. It iscontemplated that, in this embodiment, controller 28 may also beconfigured to communicate information obtained from sensors 30 a, 30 b,30 c and/or associated with the analysis performed by controller 28offboard machine 10 to, for example, a worksite base station 38 or ageneral site controller (not shown) located at base station 38. Thisinformation may then be analyzed at base station 38 and/or forwarded toother machines 10 operating at worksite 12. In this manner, electronicmap 34 may be the compilation of data simultaneously obtained frommultiple sources at multiple locations within worksite 12.

In another embodiment, controller 28 could be the general sitecontroller located at base station 38. That is, it may be possible thatthe information obtained from locating device 26 and sensor 30 is onlyanalyzed and used to generate electronic map 34 at base station 38. Inthis situation, electronic map 34 could then be communicated to eachmachine 10 operating at worksite 12. It may also be possible forcontroller 28 to then, for example, provide an alarm to an operator ofthe one or more machines 10 operating at worksite 12. Such an alarm mayindicate that machine 10 may be approaching or may be located proximateobject 40. Such objects 40 may be located in a blind spot of one or moresuch machines 10 and the operators may not be aware of the presence ofsuch objects. Alerting such operators as to the presence and/or locationof such objects 40 may enable the operators to avoid contacting theobject 40 with the machine 10.

INDUSTRIAL APPLICABILITY

The disclosed machine detection system may be applicable to any worksiteand usable with any material handling machine to generate and update anelectronic map closely matching the outer boundary of machine 10 and/orthe one or more work tools 22 connected thereto. Since the electronicmaps 34 of the present disclosure are unique to the particular machine10 and/or work tool 22, and are generated during a calibration exerciseat the work site 12, such electronic maps 34 eliminate the need forgeneric machine maps sized, shaped, and/or otherwise configured for usewith a broad range of machines and/or work tools. In particular, theindividualized electronic maps 34 of the present disclosure maximize thesensitivity of the machine detection system 32 and provide for enhanceddetection of objects located in machine blind spots. Whereas suchobjects are not easily seen by the operator and would not be detected byless sensitive generic machine maps, the electronic maps 34 of thepresent disclosure closely match the outer boundary of machine 10 and/orwork tool 22 in order to enable reliable detection of such objects. As aresult, the electronic maps 34 of the present disclosure reduce machinedamage, and resulting downtime associated with machine repair, caused byinadvertent contact between machine 10 and such objects 40. Accordingly,the exemplary embodiments of the present disclosure may increase overallprofitability of the worksite 12. Operation of machine detection system32 will now be described in detail.

In an exemplary embodiment, an operator of machine 10 may perform acalibration exercise whereby one or more three-dimensional electronicmaps 34 of machine 10 may be generated by machine detection system 32.During such a calibration exercise, machine 10 may be positioned at asubstantially flat, substantially unoccupied location in worksite 12,such as a location remote from objects 40 having any substantial size.In exemplary embodiments, machine 10 may be positioned at a location inwhich no such objects 40 may be within a sensing range of sensors 30 a,30 b, 30 c. It is understood that such a “sensing range” may be definedas a two or three-dimensional zone or area associated with such sensors30 a, 30 b, 30 c, within which objects may be sensed and/or detected byone or more of sensors 30 a, 30 b, 30 c. Objects 40 disposed outside ofsuch a sensing range may not be detected by sensors 30 a, 30 b, 30 c.While machine 10 is disposed at such a location, controller 28 maydirect sensors 30 a, 30 b, 30 c to sense the outer boundary of machine10. As a result, sensors 30 a, 30 b, 30 c may generate a first set ofinformation indicative of the outer boundary of machine 10. For example,sensors 30 a, 30 b, 30 c may generate distance, position, location,and/or other information indicative of the dimensions, contours, shapes,and/or other characteristics of the outer boundary. As described above,the outer boundary of machine 10 may include the outer boundary of worktool 22. In exemplary embodiments, each sensor 30 a, 30 b, 30 c maygenerate a respective subset of information indicative of the outerboundary of machine 10, and as noted above, the first set of informationmay comprise such subsets of info nation particular to each sensor 30 a,30 b, 30 c. Sensors 30 a, 30 b, 30 c may direct such information tocontroller 28 for analysis and/or storage in memory.

During such an exemplary calibration exercise, controller 28 may alsodirect sensors 30 a, 30 b, 30 c to sense the outer boundary of work tool22. In exemplary embodiments, operator may control work tool 22 to moverelative to machine 10 through substantially an entire range of motionthereof. For example, an operator may control work tool 22 to move fromthe fully-lowered position shown in FIG. 1 to a fully-raised position.Operator may also control work tool 22 to pivot in, for example, thefore and aft directions relative to frame 14. In further exemplaryembodiments in which a different work tool 22 is coupled to machine 10,different movement and/or ranges of motion may be used in such anexemplary calibration exercise. Sensors 30 a, 30 b, 30 c may becontrolled to sense the outer boundary of work tool 22 during suchmovement. Sensors 30 a, 30 b, 30 c may also generate a second set ofinformation indicative of the location of the outer boundary of worktool 22 as work tool 22 travels through substantially the entire rangeof motion described above. In this way, sensors 30 a, 30 b, 30 c maygenerate distance, position, location, and/or other informationindicative of the dimensions, contours, shapes, and/or othercharacteristics of the outer boundary of work tool 22 as the position ofwork tool 22 changes relative to machine 10. As described above, eachsensor 30 a, 30 b, 30 c may generate a respective subset of informationindicative of the outer boundary of work tool 22, and the second set ofinformation may comprise such subsets of information. Sensors 30 a, 30b, 30 c may direct such information to controller 28 for analysis and/orstorage in memory. Further it is understood that this process may berepeated for all machine components disposed on an outer surface thereofand configured for controlled movement relative to frame 14 and/ormachine 10 generally. In exemplary embodiments, such components mayinclude one or more additional work tools 22.

Once sensing is complete, controller 28 may modify at least one of thefirst and second sets of information generated by sensors 30 a, 30 b, 30c, and/or at least one of the respective subsets of informationdescribed above, based on a predetermined threshold factor associatedwith the machine 10 and/or the work tool 22. Such a threshold factor maybe, for example, a ratio, a percentage, an algorithm, and/or any othermathematical expression useful in tailoring the information generated bysensors 30 a, 30 b, 30 c to the particular machine 10 and/or work tool22 being used. For example, such a threshold factor may be a percentagesufficient to account for variations in the position of machine 10, worktool 22, and/or components thereof, caused by loading, movement,vibration, deflection, and/or other environmental factors associatedwith operating machine 10 at worksite 12. In such embodiments, modifyingat least one of the first and second sets of information generated bysensors 30 a, 30 b, 30 c based on the threshold factor may result in ascaled-up, enlarged, and/or otherwise “augmented” set of information.Such an augmented set of information may be indicative of a larger outerboundary of machine 10 than that sensed by sensors 30 a, 30 b, 30 cduring the initial stages of the calibration exercise. Such an augmentedset of information may also be indicative of a larger outer boundary ofwork tool 22 and/or of the range of motion of work tool 22 than thatsensed by sensors 30 a, 30 b, 30 c during the initial stages of thecalibration exercise. Accordingly, due to such modifications, the setsof information and/or subsets of information associated therewith may beindicative of a slightly larger machine 10 and/or work tool 22 than thatactually sensed by sensors 30 a, 30 b, 30 c.

In further exemplary embodiments, controller 28 may form, at worksite12, a three-dimensional electronic map 34 associated with machine 10based on the first and second sets of information described above. Asshown in FIG. 2, the electronic map 34 may be indicative of the outerboundary of machine 10, the outer boundary of work tool 22, and/orsubstantially the entire range of motion traveled by work tool 22. Insuch embodiments, controller 28 may modify electronic map 34 based onthe predetermined threshold factor described above. Accordingly, inexemplary embodiments, modifying the electronic map 34 may includegenerating an enlarged (i.e., a scaled-up) three-dimensional electronicmap 34 indicative of a larger outer boundary of machine 10 than thatsensed by sensors 30 a, 30 b, 30 c during the initial stages of thecalibration exercise. Such an enlarged electronic map 34 may also beindicative of a larger outer boundary of work tool 22 and/or of therange of motion of work tool 22 than that sensed by sensors 30 a, 30 b,30 c during the initial stages of the calibration exercise. Accordingly,due to such modifications, the enlarged electronic map 34 may beindicative of a slightly larger machine 10 and/or work tool 22 than thatactually sensed by sensors 30 a, 30 b, 30 c. The initial electronic map34 and/or the enlarged electronic map 34 may be stored in a memory ofcontroller 28, and either map 34 may be displayed at any time via theinterface device 24. As described above, such electronic maps 34 may beunique to the particular machine 10 and/or work tool 22 in use atworksite 12.

Such calibration exercises may be repeated as often as necessary atworksite 12. For example, such calibration exercises may be repeatedeach time a new work tool 22 is coupled to machine 10. For example, afirst work tool 22 may be replaced with a second work tool 22 of thesame type or of a different type than the first work tool 22. Uponconnecting the second work tool 22 to machine 10, the operator may movethe second work tool 22, relative to machine 10, through substantiallyan entire range of motion of the second work tool 22. During thisprocess, sensors, 30 a, 30 b, 30 c may sense, at worksite 12, the outerboundary of the second work tool during movement thereof through itsrange of motion. Sensors, 30 a, 30 b, 30 c may also generate a third setof information indicative of the location of the outer boundary of thesecond work tool 22 through substantially the entire range of motionthereof. Such information may be sent to controller 28 for analysisand/or storage. In exemplary embodiments, controller 28 may form, atworksite 12, a three-dimensional electronic map 34 associated withmachine 10 and the second work tool 22. Such an electronic map 34 may bebased on the first set of information described above and the third setof information particular to the second work tool 22. Thus, the newelectronic map 34 may be unique to the second work tool 22. Further, thethird set of information and/or the associated new electronic map 34 maybe modified based on one or more threshold factors as described above.

During operation, machine 10 may encounter one or more objects 40 atworksite 12, and depending on the configuration of machine 10, suchobjects 40 may be not be visible by the operator of machine 10. Forinstance, such objects 40 may be located in one or more blind spotsassociated with machine 10 and/or operator station 16. In embodiments inwhich objects 40 comprise large boulders, other machines, work siteequipment, and the like, contact between machine 10 and object 40 maycause unwanted damage to object 40 and/or machine 10. In otherembodiments in which objects 40 comprise operators or other work siteemployees, such contact may result in harm or injury. Accordingly,machine detection system 32 may be operable to detect such objects 40and alert the operator to the presence of such objects 40 in order toavoid inadvertent contact between such objects 40 and machine 10.

In exemplary embodiments, sensors, 30 a, 30 b, 30 c may determineinformation indicative of a position of an object 40 disposed proximatemachine 10 at worksite 12. For example, during operation of machine 10,sensors, 30 a, 30 b, 30 c may detect one or more such objects 40disposed within the sensing range of the respective sensors, 30 a, 30 b,30 c. Sensors, 30 a, 30 b, 30 c may determine, for example, the positionof object 40 relative to machine 10, and the information determined bysensors, 30 a, 30 b, 30 c may comprise distance, angle, and/or otherlike information. Additionally, if object 40 is moving relative tomachine 10, such information may comprise speed, acceleration, rotation,and/or other like information indicative of such movement. In each ofthe embodiments discussed herein, such information may be determined bysensors, 30 a, 30 b, 30 c in real time, and in an open-loop and/or aclosed-loop manner. Such information collected by sensors, 30 a, 30 b,30 c may be directed to controller 28 for storage and analysis. Forexample, controller 28 may determine whether the information indicativeof the position of object 40 is included in either the first or secondsets of information described above. Such an analysis may includedetermining whether the information indicative of the position of object40 is included in any of the subsets of information particular to therespective sensors 30 a, 30 b, 30 c. Further, in exemplary embodimentsin which machine detection system 32 has formed a three-dimensionalelectronic map 34 associated with the machine 10, such an analysis mayinclude determining whether object 40 is located within the electronicmap 34.

Since the exemplary sensed outer boundaries and electronic maps 34described herein closely match the actual outer boundary of machine 10and work tool 22, such sensed outer boundaries and electronic maps 34are useful for warning the operator of potential contact between machine10 and object 40. For example, if controller 28 determines that theinformation indicative of the position of object 40 is encompassed byand/or otherwise included in the first or second sets of information, orany of the various respective subsets of information associatedtherewith, controller 28 may conclude that the sensed object 40 isactually part of machine 10 or work tool 22. Likewise, if controller 28determines that the information indicative of the position of object 40is encompassed by and/or otherwise included in the electronic map 34generated based on the first or second sets of information, or any ofthe various respective subsets of information associated therewith,controller 28 may conclude that the sensed object 40 is actually part ofmachine 10 or work tool 22. In such embodiments, controller 28 maydetermine that the object 40 is located within the confines of theelectronic map 34 based on the information indicative of the position ofthe object 40. Controller 28 may not provide an alarm to the operator ofmachine 10 in response to such determinations.

On the other hand, if controller 28 determines that the informationindicative of the position of object 40 is not included in either thefirst or second set of information, and/or in any of the respectivesubsets of information associated therewith, controller 28 may, inresponse, direct one or more interface devices 24 to provide an audible,visual, tactile, and/or other like alarm to the operator of machine 10.Such an alarm may be indicative of a determination by controller 28 thatthe sensed object 40 is within a sensing range of one or more of sensors30 a, 30 b, 30 c, and is outside of the outer boundary of machine 10 andsubstantially the entire range of motion of work tool 22. In exemplaryembodiments, such a sensing range may extend up to approximately 30meters from the respective sensor 30 a, 30 b, 30 c. In further exemplaryembodiments, and depending on the configuration of the respective sensor30 a, 30 b, 30 c, such a sensing range may be greater than or less thanapproximately 30 meters. It is also understood that in exemplaryembodiments in which machine detection system 32 forms athree-dimensional electronic map 34 associated with machine 10,controller 28 may direct one or more interface devices 24 to providesuch an alarm to the operator in response to determining that object 40is not located within the electronic map 34. The alarms described hereinmay assist the operator in avoiding contact between machine 10 andobject 40. Additionally, since the outer boundaries and/or electronicmaps 34 described herein are formed, at worksite 12, to closely matchthe particular contours, geometries, and/or other configurations of therespective machine 10 and work tool 22 in use, the outer boundariesand/or electronic maps 34 of the present disclosure are not plagued bythe sensitivity and/or other deficiencies of universal software-basedfilters commonly employed by known machine detection systems.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the disclosed systems andmethods. Other embodiments will be apparent to those skilled in the artfrom consideration of the specification and practice of the disclosedmachine detection system 32. It is intended that the specification andexamples be considered as exemplary only, with a true scope beingindicated by the following claims and their equivalents.

What is claimed is:
 1. A method of mapping a machine having a work tool,comprising: sensing an outer boundary of the machine and generating afirst set of information indicative of the outer boundary of themachine; moving the work tool relative to the machine throughsubstantially an entire range of motion of the work tool; sensing anouter boundary of the work tool during movement of the work tool throughsubstantially the entire range of motion and generating a second set ofinformation indicative of a location of the outer boundary of the worktool through substantially the entire range of motion; determininginformation indicative of a position of an object disposed proximate themachine; and determining whether the information indicative of theposition of the object is included in either the first or second sets ofinformation.
 2. The method of claim 1, further including providing analarm to an operator of the machine in response to determining that theinformation indicative of the position of the object is not included ineither the first or second set of information.
 3. The method of claim 1,wherein determining that the information indicative of the position ofthe object is not included in either the first or second sets ofinformation comprises determining that the object is within a sensingrange of a sensor associated with the machine, and is outside of theouter boundary of the machine and substantially the entire range ofmotion of the work tool.
 4. The method of claim 3, wherein the sensorcomprises one of a camera and a radar device.
 5. The method of claim 1,further comprising modifying at least one of the first and second setsof information based on a predetermined threshold factor associated withthe machine.
 6. The method of claim 5, wherein modifying the at leastone of the first and second sets of information results in an augmentedset of information, the augmented set of information being indicative ofat least one of a larger outer boundary of the machine than the sensedouter boundary of the machine and a larger outer boundary of the worktool than the sensed outer boundary of the work tool.
 7. The method ofclaim 1, wherein at least one of the first and second sets ofinformation is generated by a plurality of sensors associated with themachine, the at least one of the first and second sets of informationcomprising a subset of information associated with each respectivesensor of the plurality of sensors.
 8. The method of claim 7, whereinthe subset of information associated with each respective sensorincludes information indicative of a position of a component of themachine relative to one sensor of the plurality of sensors.
 9. Themethod of claim 7, wherein determining whether the informationindicative of the position of the object is included in either the firstor second sets of information comprises comparing the informationindicative of the position of the object to the subset of informationassociated with each respective sensor.
 10. The method of claim 7,further including providing an alarm to an operator of the machine inresponse to determining that the information indicative of the positionof the object is not included in the subset of information associatedwith each respective sensor.
 11. A method of mapping a machine having afirst work tool, comprising: sensing, at a worksite, an outer boundaryof the machine with a plurality of sensors located on the machine;generating a first set of information indicative of the outer boundaryof the machine; moving the first work tool relative to the machinethrough substantially an entire range of motion of the first work tool;sensing, at the worksite, an outer boundary of the first work toolduring movement of the first work tool through substantially the entirerange of motion with at least one sensor of the plurality of sensors;generating a second set of information indicative of a location of theouter boundary of the first work tool through substantially the entirerange of motion; forming, at the worksite, an electronic map associatedwith the machine based on the first and second sets of information,wherein the map is indicative of the outer boundary of the machine, theouter boundary of the first work tool, and substantially the entirerange of motion; determining information indicative of a position of anobject at the worksite; and determining whether the object is locatedwithin the map based on the information indicative of the position ofthe object.
 12. The method of claim 11, further including modifying themap based on a predetermined threshold factor associated with themachine.
 13. The method of claim 12, wherein modifying the map comprisesgenerating an enlarged map indicative of at least one of a larger outerboundary of the machine than the sensed outer boundary of the machineand a larger outer boundary of the first work tool than the sensed outerboundary of the first work tool.
 14. The method of claim 11, wherein atleast one of the first and second sets of information comprises a subsetof information associated with each respective sensor of the pluralityof sensors, the subset of information including information indicativeof a position of a component of the machine relative to one sensor ofthe plurality of sensors.
 15. The method of claim 11, further includingdetermining that the object is not located within the map, and providingan alarm to an operator of the machine in response to determining thatthe object is not located within the map.
 16. The method of claim 11,further including storing the map in a memory located on the machine.17. The method of claim 11, further including replacing the first worktool with a second work tool different than the first work tool; movingthe second work tool relative to the machine through substantially anentire range of motion of the second work tool; sensing, at theworksite, an outer boundary of the second work tool during movement ofthe second work tool through substantially the entire range of motion ofthe second work tool; generating a third set of information indicativeof a location of the outer boundary of the second work tool throughsubstantially the entire range of motion of the second work tool; andforming, at the worksite, an additional electronic map associated withthe machine and the second work tool based on the first and third setsof information.
 18. A machine, comprising: a frame; at least onetraction device configured to support the frame and propel the machineabout a worksite; a work tool operatively connected to the frame andconfigured to move, relative to the frame, through a range of motion; asensor mounted on the machine and configured to generate a first set ofinformation indicative of an outer boundary of the machine and a secondset of information indicative of a location of an outer boundary of thework tool through substantially the entire range of motion; and acontroller disposed on the machine and in communication with the sensor,the controller being configured to generate an electronic map associatedwith the machine based on the first and second sets of information,wherein the map is indicative of the outer boundary of the machine, theouter boundary of the work tool, and substantially the entire range ofmotion.
 19. The machine of claim 18, wherein the controller is furtherconfigured to generate an enlarged electronic map based on apredetermined threshold factor associated with the machine, the enlargedmap being indicative of at least one of an enlarged outer boundary ofthe machine and an enlarged outer boundary of the work tool.
 20. Themachine of claim 18, further comprising a plurality of sensors incommunication with the controller, wherein at least one of the first andsecond sets of information comprises a subset of information associatedwith each respective sensor of the plurality of sensors, the subset ofinformation including information indicative of a position of acomponent of the machine relative to one sensor of the plurality ofsensors.